Expandible plastic mold



s. H. A. YOUNG 2,363,107

EXPANDVIBLE PLASTIC MOLD Nov. 2l, 1944.

Filed July 19, 1941 `4 Sheets-Sheet 2 n-n n-n @@2. n a

INVENTOR.

'BYW n or/Tp s. H. A. YOUNG EXPANDIBLE PLASTIC MOLD Nov. 2l, 1944.

Filed July 19, 1941 4 Sheets-Sheet 3 Bde/@nus Nov. 2l, 1944. l s. H. A. YOUNG EXPANDIBLE PLASTIC MOLD 4 Sheefs-Sheet 4 Filed July 19, 1941 Patented Nov. 21, 1944 EXPANDIBLE PLASTIC- MOLD Serenus H. A. Young, Oak Park, Ill., assignor to JesseB. Hawley, Geneva, Ill.

Application July 19, 1941, Serial No. 403,101

2 Claims.

This invention relates to a mold for molding plastic materials, and more particularly to such mold having an expendible element for exerting the pressure on the article being molded in which mold the heretofore necessary extremely large capacity, size and power for the press is obviated.

The particular phase of the plastic molding art to which this invention relates is that of compression molding, in which the use of thermosetting plastic materials predominates as distinguished from that phase of the molding art known as injection molding, wherein thermoplastic materials are principally used. This invention further relates particularly to the art of molding accreted brous contoured plastic articles, which diifers, among other ways, from the conventional phenolic and urea compounds in that in the present invention the articles are initially accreted or preformed to substantially the same shape and contour as will be possessed by the finished molded article. In the old methods heretofore known, conventional thermosetting phenolic and urea compounds are used principally in the form oi' granules, which when placed in the mold and subjected to heat and pressure flow to the extent necessary to fill the space between the male and female portions of the mold. In the present invention, the accreted, contoured plastic materials referred to are in substantially their final position and hence a minimum of flow is required.

Heretofore, it has been conventional practice when molding thermosetting plastic materials, to place a measured quantity of the powder or granules into the mold cavity and, when subjected to heat and pressure, these materials flow through considerable distances in following and filling the contour defined by the mold. While some articles have been satisfactorily molded by such old method, limitations imposed by equipment and flow properties of conventional plastic materials has precluded the possibility cf molding very large parts.

It is an object of the present invention to provide an apparatus by which articles of comparatively large size and intricate contour can be satisfactorily molded, and to avoid the limitations to which conventional plastic materials and methods are subjected.

Further, the molding of conventional plastic materials of the type specifically known as high impact materials, has been severely limited as to size and contour because, although conventional plastic materials are dependent on their ability to flow to iill the mold space, the high impact material is characterized by a low ilowability. It is accordingly another object of the present invention to provide an apparatus for moldingaccreted contoured' plastic articles which possess high impact qualities without encountering the difficulties normal to the molding ofconventional high impact materials.

In the operation oi' the molding apparatus of the present invention, the physical loads. or stress involved in the molding operation are utilized and distributed in a manner quite different from that used in conventional molding practice. For example, in the conventional method, all the pressures exerted on the mold cavities proper and on the molding material in the cavity are equalized to the pressure developed in the hydraulic cylinder exerting the pressure on the mold.-n In the present invention the main hydraulic cylinder (which is directly comparable to a similar cylinder used in a conventional molding press) is used merely to raise and lower the upper portion of the die and its supporting structure. When the press and the mold are locked together in closed position and fluid pressure exerted behind the flexible member, an upward force equal to the unit pressure back of the flexible member multiplied by the projected area of the mold cavity is developed and must be resisted to prevent opening of the mold. In the conventional mold and press system, this upward force would resolve itself into tension loads to be carrled by the posts or columns. This, of course, requires very heavy construction of presses where pieces of large size are to be molded.

In the present invention none of the physical loads of molding is taken by the structure of the press itself, but are carried by an especially strong arrangement of parts provided for holding the male and female parts oi' the mold together. The load involved in the molding process is confined first tothe mold, and second to the parts holding the molding die parts together, with none of the heavy loads being taken by the press structure itself. This means that the excessively high cost of heavy molding press equipment is entirely eliminated, and further that the size of the article to be molded is limited only by the size of the mold obtainable, which are further objects of this invention.

In conventional molding of plastic materials,E hydraulic presses are principally used. Normal pressure of 2,000 to 4,000 lbs. per square inch on the projected area of the article to be molded are current practice. If, for example. an article to be molded has an area of 2,000

square inchesfa hydraulic press having arca!- pacity of 2,000 to .3,000 tons would required 'to produce a--satisfactorymolding by conven tional methods. In the present invention, however,-in molding an article of similar size, a hydraulic presswith a capacity not exceeding 25 tons would beA employed, notwlthstinding the different areas of the article being molded. In

` the present invention, where flowability of the plastic is not a, factor because the accreted contoured plastic preform is substantially in final shape and position before pressing actually takes place, the expandible member of the mold exerting a uniform pressure over the entire area of the preform, such preform possesses very uniform characteristics when the molding process has been completed.

The present invention further contemplates whereY necessary the inclusion of accreted inserts to be placed anywhere desired on the surface of the main preform to permit the molding of the accreted contoured plastic articles having non-uniform sections. Such inserts, however, are not limited to those made .of accreted material but may also include metallic inserts threaded, knurled or otherwise treated befo insertion in the molded article.

A further object of the present invention is the provision of apparatus and means for felting, transferring and extracting water from resin-fiber plastic performs, as will later be more fully described.

A further object of the present invention is the provision of a novel apparatus for molding accreted fiber-reinforced plastic articles under heat and high pressure. in which is provided a mold having a pair of dies with a cavity of the desired shape therebetween. a resilient member covering one face of the cavity wall. means for clamping the two dies firmly together in such manner as to resist great pressure between the dies and applying great pressure behind the back face of the resilient member so as to exert a large uniform pressure against the accreted fibrous plastic article being molded without the necessity of a large and heavy press.

Other` objects, advantages and capabilities will later more fully appear.

My invention further resides in the combination, construction and arrangement of parts illustrated in the accompanying drawings, and while I have shown therein preferred embodiessaie? ments wish it understood that the vsame are susceptible lof modication and change without -departing from the spirit of my invention.

In the drawings- Fig. 1 is a'side elevation of a molding apparatus embodying the present invention, with the male and female dies of the mold shown in vertlcal transverse section through a median plane.

and with the mold shown in closed and clamped position.

Fig. 2 is a view similar to Fig. i but showing the male and female dies in open position, and with the clamping means in open position.

Fig. '3 is a diagrammatic view showing one With reference to the mold itself, the present form of hydraulic system to be used for the' exinvention provides numerous advantages over pansion of the expandible part of the mold. conventional molding methods. It ls very often Fig. 4 is a vertical transverse section through the case in conventional molding practice for a tank containing aiiber-water bath and showexcessively high loads to be applied within the ing a fibrous preform accreted onto a porous molding cavity in the rst part of the molding former. cycle, during which time the materials are being Fig. 5 is a vertical transverse section showing plasticized and during which time the plastic a modified form o! the expandible member and materlals'possess little flowability. Such excesits supporting connections.

' sive high loads being eliminated in the present Fig. 6 is a fragmentary Vertical transverse invention, very greatly lessen the cost of the section through a portion of the expandible molding die. Further, it often happens in conmember and its supporting means showing a. furventional molding practice that inasmuch as ther modified form. conventional plastic molding material will not Fig. 7 is a vertical transverse-section of a feltact as a true fluid when plastlcized in the mold, ing tank showing a porous former immersed in ,a varying pressure values will be obtained on fiber-Water' bath in pOSiiOn ready t0 have'the fibers accreted thereon.

Fig. 8 is a vertical transverse section of a transferring device and showing the accreted preform on the porous former in position therein just prior to removing the former and transferring the carcass to the water pressing device Fig. 9 is a vertical transverse section of the transfer device after the accreted perform has had the porous former removed therefrom, and the preform transferred to and applied over the -water extractor assembly.

Referring more in detail to the drawings, I have shown in Fig. 1 an apparatus for carrying out my invention and comprising a frame A having supporting legs I having mounted thereon a stationary support or" bottom platen 2, in which is mounted the A-upstanding posts 3 preferably having integral collars l near their lower ends, which in conjunction with the nuts 5 hold posts a in nxed position with relation to the stationary support 2. Adjacent the upper end of each of posts 3 is an integral collar 8 forming a support for the upper stationary plate or cross support 1,

which is secured in stationary position on posts 3 by nuts 8.'

Mounted upon the upper plate 1 is a hydraulic cylinder 9 having the usual hydraulic piston therein, and the piston rod I0 which projects downwardly from cylinder 9, and mounted on the lower end of which for vertical movement with 'piston rod I0 is the head or top platen Il. The top platen or head Il is thus seen to have vertical movement with the plunger l0 underlinuence of the pistonvhead in the hydraulic cylinder 9 when uid is introduced into the hydraulic cylinder. Secured to the lower face of the top platen Il are cross bars I2 to which are secured the top plate Il of the male die, there being fixed in any suitable manner to the bottom face of plate I3 the depending'portion I4 of the male die. It is thusseen that the male die will have upward and downward movement with the plunger I0 when desired.

Secured to the bottom platen 2 are the cross bars l5 upon which are mounted in any desired ing portion of the male mold isassale? manner the female die Il provided with a series of openings I1 which intercommunicate topermit the entry of steam or other heating medium as desired for heating the female die I8. Screwed into the upper portion of the female die i8 are pins I8 which slidably enter openings Il in ther plate I2 of the male die to bring these two dies when closed rinto proper registry. Positioned over the depending portion I4 of the male die is the resilient expandible member 28 which is preferably of rubber or other suitable resilient material,

and which merely rests against the outer face of the-depending portion I4 of the male die except at the upper edge 2 lwhich edge extends inwardly into a complemental groove and is clamped therein between the depending portion i4 and the plate Il to hold the expandible member 2 8 unattached over the outer face of the depending portion of the male die except where it is attached at the upper edge 2| as described above. Extending downwardly at one side of the dependa passageway A22 leading at the bottom into the laterally extendingA passageway 23, which latter passageway opens behind the expandible member 28.

` Screwed or otherwisefixed to the upper portion of plate I3 and in alignment with passageway 22, is a pipe or other suitable conduit 24 leading to any suitable source of supply of water or other fluid under pressure, so that when said duid is introduced through pipe 24 and through passageways 22 and 23, the expandible member 28 will be distended or expanded by reason of the pressure of such fluid. I preferably use water as the fluid referred to, but wish it understood `that any other suitable :duid may be used as desired. Formed in the opposite side of the depending portion of the male die is a downwardly extending passageway 25, the lower end of which connects with the laterally extending passageway 28 leading to the rear or inner face of the expandible bag 20, so that the water or other fluid used for expanding said expandible member may find its way out through passageways 28, 25 and outlet pipe 21. l

When the male and female dies are in open position as shown in Fig. 2, the accreted fibrous pulp carcass or preform 28 will be placed either within the cavity of the female die or placed over the expandible member 28 of the male die, so that when the dies are closed said preform will substantially fill the cavity between the two dies and under influence of heat from the heating passageways i1 and pressure of water or other fluid introduced through pipe 24 be molded to form a plastic article by reason of the resin carried by the fibers of the preform becoming plastic and illling the interstices between and around said fibers to thoroughly embed the fibers in the plastic material.

Any shape of preform and finished article may be used as desired, one form being shown in Figs. 1 and 2, another form being shown in Figs. 7 to 9, and, as will be understood, many different forms may be adopted as desired, the number of forms and shapes being only limited by those of the articles to be made. 'I'he preforms are initially made by accreting in a fiber-water bath 68 in a tank 81 (see Fig. 4) upon a porous former, suction being applied to the interior of the porous former through a hose or other flexible conduit 32', from any suitable vacuum line. When desired, the direction of flow of the air with relation to the former may be reversed.

the nbers are secreted onto the porous i'elting former will be deposited on and in the nbersoi the carcass being thus secreted.' In other words, the iibers will have coated thereon and to a certain extent impregnated therein resin whereby after the carcass or preform has been dried and placed in the mold of Fig. 1 under heat from the heating medium in openings I1 and high pressure eil'ected by water or other fluid through pipe 24 and passageways 22, 23 to the rear or inner face of the expandible member 28, the resin will become plastic and ilow into the interstices between the fibers of the preform and completely embed the fibers' in the resin to form a dense', iiberreinforced plastic article in which the liber relnforcement is made from a preform of accreted resin carrying bersv of the same shape and the same size except for the decrease in thickness Y f during molding as the article is being molded.

The plastic material does not ilow any substantial distance longitudinally in the mold but generally in a direction of the thickness of the mold. It is thus seen that the resin and fibers are in substantially their final position except for the` application of heat and pressure to bring them together andl render the resin plastic.

Some of the resins that may be added to the bath or, if desired, applied by spraying, dipping, painting or the like, are synthetic resins, thermosetting resins such as phenol-formaldehyde, phenol-furfural and urea formaldehyde, thermoplastic resins and natural resins such as lignin, vinsol and the like. The foregoing are merely givenas examples of some of the resins that may be used, and are not intended to be exclusive as other suitable resins may be used as desired.

It is important to note that the pressure applied to the preform during the molding operation is not applied by the hydraulic cylinder 9, as the latter is merely for raising and lowering the upper die and holding the dies in closed -position preparatory to application of the clamping means for clamping the two parts of the mold together, which clamping means will now be described.

Mounted upon the lower face of the bottom platen 2 is a hydraulic cylinder 31 having the usual piston (not shown) and plunger 38, this plunger being pivotally attached at 38 to the 4toggle links 40 and 4I, link 40 being pivoted at 42 to the lever 43 and link 4| being pivoted at 44 to the lever 45. Lever 43 is pivotally mounted to the heavy pin 46, while lever 45 is pivotally mounted to the heavy pin 41.

As each of the levers 43 and 45 is of the .same construction at the upper` end, only one of them will be described, it being understood that the other is of a similar construction but reversed in position so that these ends move toward and away from each other. The upper end of each of these levers 43 and 45 is formed with the inturned arm 48, to which is pivotally mounted at 49 the cam 50, to which cam is fixed an arm 5i pivoted at 52 to the plunger 53 longitudinally movable in the hydraulic cylinder 54, so that when said cylinder is operated to move plunger 53 the cam 50 will be rotated to either tighten or loosen the cam against thehardened metal plate 55 carried one at each end as shown in Fig. l of the top platen II. It will be understood that suflicient play will be permitted between the parts to permit articulation of plunger 53 and arm 5I Without binding of the parts.

-Tnere :sanded to the bath n a suitable mm. y preferably a water soluble resin, which resin when When theparts are inthe position shown in Fig. 2, the plunger 33 of hydraulic cylinder 31 will be moved to its maximum limit upwardly to move the upper inturned ends 48 of levers 43 and 43 outwardly away from the top platen Il to clear the same, there being formed in the end edges of the top platen Il, grooves or recesses 58 to 4permit tcp platen I I -to move. upwardly and downwardly past the cams |50 when the upper ends of the levers 43 and 45 stand in their open or outermost position. As will 'also be understood, each of the corner portions of top' platen Il will be grooved to have sliding engagement with posts 3 as indicated at 51 in Figs. 1 and 2. After the upper platen Il is moved downwardly to bring the depending portionof the male die into the cavity of the female die-I6, the hydraulic .cylinder 31 will be operated to move the plunger 38 downwardly into the position shown in Fig. 1, which will move the upper inturned ends 48 of the levers 43 and 45 inwardly to bring the two camsv 50. 4directly over the hardened plates 55 as shown in Fig. 1. Application of power to each of the hydraulic cylinders 54 will cause the plungers 53 to move upwardly and move vthe arms 5l and turn the cams 50 into clamping engagement with plates 55 to tightlyv clamp and hold the upper and lower dies together. The

parts, especially the pins 46, 41 and levers 43v and 45, will be of sturdy construction as they take the strain of the molding pressure applied to the inside of the mold cavity.

Itis thus seen that I have provided a mold for molding plastic materials in which large pressures may be used withoutthe necessity of providing a large and heavy press, as when the two parts of the mold are fastened together the molding pressure will be applied internally of the dies instead of externally through heavy and cumbersome mechanical presses, these internal pressures being absorbed by the clamping means described above. When the two diesof the mold are locked together as described above, with a fibrous accreted resin impregnated preform in position in the cavity of the mold, wateror other fluidv is introduced through'theff-pipe 24 back of the expandible member so as to force. said expandible member in all portions of'its circumference and other parts with a uniform pressure against the preform. The female die as described abov`e being heated and the preformcompressed with a pressure of any desired magnitude, the resin in the preform will become plas-v tic and will be compressed around the fibers to fill the interstices therebetween andcompletely embed the fibers within the plastic article thus formed. After building up suitable pressure behind the expandible member 2li, thel uid passes through the outlet pipe 21 and through a pressure release valve shown in Fig. 3 in the hydrau-` lic system, which will now be described.

In Fig. 3 is shown a hydraulic system which of the expandible rubber or other resilient meme.

ber 20, the ,fluid continues its passage through outlet pipe 21 and through the operatingY valve 63 to the relief valve 64 preset to any desired pressure below that to which the fluid is subvalve 34, the fluid returns to the supply tank 8|. The relief valve 34 isset at a pressure below that to which the uid is subjected in the pump 30 in order that a continuous flow of the iiuid may be provided through the mold while maintaining the uid under the desired pressure,

thus permitting the fluid to be kept at the proper pressure and at the same time allowed to have a clear passage through the expandible portion of the' mold back to the-supply tank, 'and which system will prevent the iluid from exceeding the temperature of its'boiling point.

A pressure gauge 33 is provided in the return line 21. When desired, the handle 33 of the operating valve 33 may be operated to divert the flow of fluid from the relief valve 44 and pass it directly tothe supply tank Il, thus affording the use. of any pressure desired below that at which the relief valve 34 is set. This renders more flexible the range of pressures that may be used in the molding operation.

, Fig. '7 shows a tank 3l for containinga fiberwater bath' 23 in which is immersed a porous felting former 3l for accreting a preform thereon of the shape shown in Figs. 8 and 9, a flexible hose 32 similar tothe hose 32' in Fig. 4 being used to permit the porous former to be moved into and out of the bath. In general, the accreting oper-- `ation carried out in the apparatus shown in Figs. 4 and 'I is the same, the only difference being in the particular shape of the carcass'or preform being accreted. In Fig. 7 the air will be controlled by a valve 36 operating in a header 33 to connect the hose 32 with either the air line 35 or the vacuum line 34 as desired.

Fig. 5 is a modification showing an expandible member 20', which may constitute the depending portion of the male die and being completely closed except for the inlet connection for the pipe 24 and the outlet pipe 21. In this form the expandible member will itself constitute the depending portion of the male die, and will be expanded by the application of fluid pressure on its interior.

Fig. 6 sh'ows -a similar construction of expandible member except that the rubber of the expandible member 20" is calendered to fabric 63 in ordei` to control the region of expandibility and enable connection with the top In Figs. 8 and 9, I have shown a transfer and pressing apparatus in which n o exterior press is needed, but the pressing is like in Figs. l and 2 carried out inside of the apparatus.

Afterthe carcass has been formed on the porous former 3| of Fig. '1, the former together with the carcass 10 is moved upwardly out of the bath and into the transfer housing 1|, which has xed to its bottom edge and positioned on the interior of the housing a perforated metal preformshroud 12 within which the preform carcass 10 is positioned, after which the base 'I3 of the felting form is clamped to the bottom of the transfer housing 1| by any suitable clamping means 14 of which any number may be used around the circumference of the housing. When the felting form with its preform carcass is within the transfer housing, the vacuum on line 34 is cut oif and air through line 35 is turned on to exert the pressure inside the preform carcass to cause it to expand outwardly against the inner Jected in the pump 60. Upon passing the relief wall of the perforated shroud 12. At the same time suction is introduced through the line 1i and the air pressure through line 13 is cut ofi',

thus through conduit 11 setting up a suction on the interior of the transfer housing 1| to draw the preform carcass against the interior of the shroud 12 to assist the preform carcass to adhere to the inside of the shroud. During this operation a small portion of the water in the preform carcass is extracted and drawn through the conduit 11 and vacuum line 15. The air line 35 is then cut oil. and the vacuum line 34 opened. and the porous ielting form returned to the bath 29 in tank 30 to have another preform carcass accreted thereon to start another cycle. The transfer housing 1| is then moved together with its preform carcass to a place over an extractor assembly 18, and either lowered thereover or the latter moved upwardly into the carcass preform and the clamps 19 (of which any number desired may be used) are tightened to clamp the parts together.

'I'he extractor assembly comprises a base 80 having the upstanding stem 8| which is formed at its bottom with the enlarged threaded portion 82 having a washer 83 and a nut 84, between which washer and base by means of the nut, is clamped the bottom ange 85 of the upstanding expandible member 86 formed of rubber or other suitable resilient material. The stem 8| is formed at its upper end with a pair of spaced collars 81, 88, between which is tightly held the upper end ofthe expandible member, which between these washers is formed with an-opening to surround 'that portion of the stem between said collars.

Extending upwardly from the top of stem 8| is a projection 89 which passes through an opening in the preform carcass and into the upstanding portion 90 of the shroud, which at this portion is of smaller diameter than elsewhere. Shroud 12 is formed with a large number of holes 9| through which the excess water from the carcass is pressed when the expandible member 86 is expanded by fluid pressure exerted through pipe 92 and passageways 93, 94 and 95 into the interior of the expandible member. Water is preferably used but any other suitable fluid may be used as desired. I

When this fluid pressure is. applied to the interior of the expandible member, the latter will assume the position shown by the dotted lines in Fig. 9 and continued pressure therewithin will press the wet preform carcass against the shroud 12 and force a certain amount of water through said openings 9|. This water will collect in the bottom portion of the transfer housing 1| and be carried away by a vacuum exerted through conduit 11 described above. When suilicient water has been pressed from the carcass 19, the vacuum will be cut off and through manipulation of the valve 99, air pressure from pipe 18 will be exerted through conduit 11 to loosen the carcass 1|) from the shroud 12 after the iiuid pressure has been released on the interior of the expandible member 9C, `and the clamping means 19 loosened and the extractor assembly removed from the preform carcass. The carcass 10 may then be removed from the shroud 12 for further processing, such as drying and molding. The transfer housing may then be returned to the tank 30 to receive another preform carcass and for the carrying out of another cycle. The air line 16 and vacuum line 15 are controlled by a valve 99 through the head 98, so as to connect one or the other of these pipe lines as desired to the conduit 11.

While in Figs. 'l to 9 a conical preform has been shown, it will be understood that this apparatus and method is equally applicable vvto prei'orms of the shape shown in Figs. 1 and 2 or other shapes as desired. Fastened in the top of the transfer housing 1| is a rod |00 for actuating the transfer housing in vertical or other planes as desired.

Having now described my invention, I claim:

1. In apparatus for molding brous plastic articles, a frame having a bottom platen, a die on said bottom platen, means for heating said die, a second die complemental to the first mentioned die, said dies when seated together having a cavity therebetween of the shape and size of the article to be molded, a top platen on which said second die is mounted, a power cylinder on the frame and having a plunger to which the top platen is secured for vertical movement with the plunger, a pair of levers pivotally mounted on the frame, each of said levers having an inturned upper end, a cam on each oi said inturned ends, power means for rotating said cams with relation to said ends for clamping them against said top platen, and for clamping the dies between said top and bottom platens, a power cylinder secured to the bottom platen, a plunger movable into and out of said last mentioned power cylinder, a pair of toggle links connected from the last mentioned plunger to said levers whereby movement of the last mentioned plunger will move the cams inwardly or outwardly of the top platen, an expandible member in said cavity, and means for directing fluid pressure against one side of the expandible member to mold an article in the cavity to form a molded plastic article.

2. In apparatus for molding under high pressure, fibrous plastic articles, a frame having a stationary support, a die on the stationary support, means for heating the die, a second die complemental to the iirst mentioned die, said dies when seated together having a cavity therebetween of the shape of the article to be molded, a power cylinder on the frame having a plunger connected to the second die for imparting movement thereto, a pair of levers pivotally mounted on the frame, a rotatable cam on one end of each of the levers, power means for rotating said cams for clamping the two dies together, a power cylinder on the stationary support, a plunger movable into and out of the last mentioned power cylinder, a pair of toggle links connected from the last mentioned plunger to said levers for swinging the levers, an expandible member in the cavity, and meansi'or directing fluid under high pressure against o ne side of the expandible member.

BERENUS H. A. YOUNG. 

